Scented bowling balls and methods

ABSTRACT

A bowling ball including a rubber material and at least one fragrance. The rubber material may be substantially nonporous and substantially rigid. Polyurethane may be used as the rubber material. The bowling ball may, optionally, include a pigment. A method by which the bowling ball is formed includes dissolving the fragrance in a polyol, adding a catalyst, introducing the mixture into a mold, and polymerizing the mixture.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of application Ser. No. 09/832,141,filed Apr. 9, 2001, pending. The disclosure of the previously referencedU.S. patent application is hereby incorporated by reference in itsentirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to bowling balls and to methodsfor manufacturing bowling balls. In particular, the present inventionrelates to scented or fragrant bowling balls, as well as to methods forfabricating such bowling balls. The present invention also relates toother articles of manufacture that include substantially rigid,nonporous, scented rubber or rubber-like material.

2. Background of Related Art

Conventionally, bowling balls have been formed from machinable,thermosetting plastic materials. A typical bowling ball that meets thecriteria that have been set by the American Bowling Congress (ABC) hasan outside diameter of between 8.500 and 8.595 inches, providing such abowling ball with a circumference of about 27 inches. In addition, ABCstandards require that a bowling ball be within 0.010 of an inch of aspherical shape. The Women's International Bowling Congress (WIBC) hasalso set size limitations for balls used by members competing in itsevents.

The materials from which bowling balls may be formed may besubstantially homogeneous, forming a solid, substantially unitarystructure. Alternatively, a bowling ball may include a core or one ormore other weighted members that are formed from a material or materialsthat differ from the material of the outer shell thereof. Typically, hematerials from which a core or any other weighted members are formedhave greater densities than the outer shell of such a bowling ball.

Polyurethanes are an example of a material from which bowling balls orthe outer shells thereof may be formed. Polyurethanes are polymers thatare typically produced by reacting a polyisocyanate, sometimes referredto as an “A-side,” with a material that includes alcohol groups, whichis known in the art as a hydroxyl-containing material and is sometimesreferred to as a “B-side” of the polyurethane. Examples of B-sidematerials that may be used to produce polyurethane include the polyolsthat are derived from propylene oxide and from trichlorobutylene oxide.In a so-called polycondensation reaction, where a polymer and water,alcohol, or another simple molecule are the products, the A- and B-sidemolecules combine to form the polyurethane. The following chemicalequation illustrates the basic reaction between the A-side (R′NCO) andthe B-side (R₂OH) to form polyurethane:

R′NCO+R₂OH→R′NHCOOR₂,

where R and R′ are each hydrocarbons.

In use, bowling balls are subjected to the often objectionable smells ofa bowling alley, including cigarette smoke, sweat, and show odors. Afteruse, bowling balls are often placed into a bag that includes otheritems, such as gloves, supports, or braces that are used in bowling, aswell as bowling shoes. Thus, even when stored, bowling balls are oftenexposed to somewhat objectionable odors. Further, bowling bags aresometimes stored in the trunks of cars, which may carry otherundesirable smells.

Unfortunately, polyurethane, from which bowling balls are typicallymanufactured, as well as other materials that may be used in themanufacture of bowling balls, often possess some capacity to absorb theodors to which they are exposed. Moreover, some bowlers find the smellsof the materials from which bowling balls are made objectionable. Insome instances, the scents of such materials may even cause physicalreactions, such as nausea or headaches.

In use, a bowler typically positions a bowling ball in close proximityto his or her nose, where the often objectionable smells carried by thebowling ball become readily apparent to the bowler.

Accordingly, there is a need for bowling balls and other articles ofmanufacture with pleasant scents, as well as for methods formanufacturing such articles.

SUMMARY OF THE INVENTION

The present invention includes scented bowling balls and methods formanufacturing scented bowling balls. Other scented articles ofmanufacture that are formed from substantially nonporous rubber orrubber-like materials are also within the scope of the presentinvention, as are methods for fabricating these articles of manufacture.

The size and weight of a scented bowling ball incorporating teachings ofthe present invention are preferably within the specifications that havebeen set by the United States Bowling Congress, although bowling ballsof other dimensions and weights, including child-sized bowling balls,and toy bowling balls are also within the scope of the presentinvention. A bowling ball according to the present invention is formedfrom a substantially nonporous, substantially rigid rubber orrubber-like material, such as polyurethane, that has fragrance dispersedat least partially therethrough. Other articles of manufacture that arewithin the scope of the present invention include one or more componentsthat are similarly formed from a substantially nonporous rubber orrubber-like material with fragrance dispersed at least partiallytherethrough.

In the method of the present invention, fragrance is added to a liquidprecursor material and mixed therewith, preferably to homogeneity.Accordingly, it is preferred that the fragrance be compatible with theliquid precursor material. For example, if the liquid precursor materialis hydrophobic (i.e., 37 water-hating” or oil-based), the use of ahydrophobic fragrance is preferable. Alternatively, if the liquidprecursor material is hydrophilic (i.e., “water-loving” or water- oralcohol-based), a hydrophilic fragrance may be used. In the example offorming a polyurethane structure, a hydrophilic or water-based fragrancemay be mixed with a fraction of the polyol portion of the polyurethane.The amount of fragrance in the liquid precursor may then be diluted byadding more of the liquid precursor to the mixture.

Once the liquid precursor includes an amount, or concentration, offragrance that will provide a final product with the desired scent, theliquid precursor material may be cured. In the case of the formation ofa polyurethane structure, the polyol liquid precursor material may becured by adding isocyanate, a catalyst. Preferably, the isocyanate andpolyol are quickly blended with one another to for a homogeneousmixture, then introduced, or cast, into a mold. The material is thencured or permitted to cure for a length of time and by one or moreprocesses that depend, at least in part, upon the type of material thatis being used to form the article of manufacture.

Upon adequate curing of the nonporous, hard rubber or rubber-likematerial, so-called “finishing” processes may be conducted to furtherdefine the article of manufacture from the scented, substantiallynonporous, hard rubber or rubber-like material.

Other features and advantages of the present invention will becomeapparent to those of ordinary skill in the an through consideration ofthe ensuing description, the accompanying drawings, and the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which illustrate exemplary embodiments of variousaspects of the present invention:

FIG. 1 is a schematic representation of a process by which a fragrancemay be mixed with a liquid precursor material to form a hard rubber orrubber-like material, which will be used to form an article ofmanufacture;

FIG. 2 schematically illustrates the addition of more liquid precursormaterial to the mixture shown in FIG. 1 to decrease the concentrationof, or dilute, the fragrance;

FIG. 3 is a schematic representation of the application of a vacuum tothe mixture of either FIG. 1 or FIG. 2 to substantially remove gas andgas bubbles therefrom;

FIG. 4 schematically represents introduction of the mixture of FIG. 3and a catalyst that facilitates curing of at least the liquid precursormaterial through a static mix element and into a mold.

FIG. 5 is a schematic representation of the removal of an article ofmanufacture, in this case a bowling ball, from the mold of FIG. 4A and

FIG. 6 is a perspective view of a finished bowling ball.

DETAILED DESCRIPTION OF THE INVENTION

An exemplary embodiment of the present invention, in which a scentedbowling ball is formed from polyurethane is depicted in FIGS. 1-6.

In FIG. 1, a mixture 16, including a quantity of a liquid polyol 10,which is a precursor material that is also referred to herein as a“B-side” of the polyurethane, and a quantity of a fragrance 12, isformed. Mixture 16 may also include a quantity of pigment 14.

Liquid polyol 10 may be any know type of liquid polyol (e.g., apolyester polyol, a polyether polyol, etc.) that is useful in formingpolyurethane. Preferably, liquid polyol 10 is suitable for use informing substantially rigid, nonporous polyurethane, such as is used informing bowling balls and other solid articles of manufacture. Forexample, the liquid polyol available from HK Research, Inc. of Hickory,N.C., as product no. VCB 1275 may be used in a method incorporatingteachings of the present invention to form polyurethane having thedesired characteristics.

When polyurethane is being used to manufacture an article such as abowling ball, fragrance 12 may be either water-based or oil-based. Dueto the high hydrocarbon and hydroxyl contents of polyols, bothwater-based and oil-based fragrances 12 may at least partially dissolvein polyol 10. It is preferred that fragrance 12 comprises a materialsuch as an ester, a terpene, an aldehyde, a ketone, or any combinationthereof. Any portion of fragrance 12 that does not dissolve in polyol 10may be dispersed therethrough and maintained in suspension by blendingpolyol 10 and fragrance 12 just prior to or as the A-side isocyanate 22(FIG. 4) is blended with mixture 16. HK Research manufactures anexemplary isocyanate under the designation VCA 1100.

In addition, if mixture 16 includes a pigment 14, it is preferred thatfragrance 12 be compatible with pigment 14, as well as any othermaterials that are added to mixture 16, including any catalyst orA-side, such as isocyanate 22 (FIG. 4). It is also preferred thatfragrance 12 does not chemically react with polyol 10, pigment 14,isocyanate 22, or any other materials that are included in a finalpolymer blend 30 (FIG. 4) in a manner that will inhibit a polymerizationreaction between polyol 10 and isocyanate 22 or otherwise undesirablyalter the characteristics of a finished article of manufacture 40 (FIG.6) or in a manner that will substantially mask the aroma given off byfragrance 12. Further, it is preferred that fragrance 12 be stable attemperatures to which both mixture 16 and final polymer blend 30 will besubjected.

The amount of fragrance 12 that is added to polyol 10 may depend uponthe strength of scent that is desired for finished article ofmanufacture 40 (FIG. 6), the desired duration for which finished articleof manufacture 40 retains the aroma of fragrance 12 any masking of thearoma of fragrance 12 by the scent of or reaction of fragrance 12 withone or more of the other materials of mixture 16 or final polymer blend30 (FIG. 4), other factors, or combinations thereof. The strength of thearoma given off by fragrance 12 may be determined, at least in part, byone or more of the type of fragrance 12 that is used, the aroma offragrance 12, the type of material or materials in which fragrance 12 isdissolved or dispersed, and the aroma of the material or materials inwhich fragrance 12 is dissolved or dispersed. Of course, since morematerials will be added to mixture 16, the fragrance 12 may be much moreconcentrated in mixture 16 than in a final polymer blend 30.Accordingly, the amount of fragrance 12 that is included in mixture 16is determined on the basis of the desired fragrance 12 concentration infinal polymer blend 30 rather than the concentration of fragrance 12 inmixture 16. By way of example only, fragrance 12 may comprise up toabout five percent, by weight, of the combination of polyol 10 andfragrance 12 in final polymer blend 30. In one embodiment, theconcentration of fragrance 12 in a polyol 10 and fragrance 12 mixture isabout seventeen pounds of fragrance 12 for every 900 pounds of polyol10, which amounts to a concentration of about 2%. by weight, of thecombination of polyol 10 and fragrance 12.

Fragrance 12 may have any type of aroma, including, without limitation,the scents of fruits, mint, herbs, and the like. The scent of fragrance12 may or may not correspond to the color of the finished bowling ballor other article of manufacture. By way of example only, fragrance 12could be selected to impart a purple article of manufacture 40 (FIG. 6)with a grape or violet (flower) scent; a green article of manufacture 40with a sour apple or wintergreen scent; a red article of manufacture 40with a cherry, watermelon, raspberry, rose, or cinnamon scent; a yellowarticle of manufacture 40 wit a lemony smell; a blue article ofmanufacture 40 with a blueberry or peppermint scent; an orange articleof manufacture 40 with the fragrance of an orange, etc. Fragrances 12that are typically associated with aromatherapy and deodorizing andother scents may also be used, as may combinations of fragrances 12having different scents.

If included in mixture 16, a selected pigment 14 imparts a polyurethanearticle of manufacture 40 (FIG. 6), such as a bowling ball, with itscolor. As with fragrance 12, pigment 14 may be either water-based oroil-based and preferably dissolves substantially within the B-sidepolyol 1. The amount of pigment 14 that is blended with polyol 10depends upon the desired intensity of the finished product Of coursessince additional polyol, 10 may subsequently be added to mixture 16 andisocyanate 22 (FIG. 4) will be added to mixture 16, the concentration ofpigment 14 in mixture 16 is relatively high compared to theconcentration of pigment 14 in final polymer blend 30 (FIG. 4).

In an exemplary process for forming mixture 16, an initial quantity ofpolyol 10, along with desired quantities of fragrance 12 and pigment 14,may be added to a dispersing tank 17. Fragrance 12 and pigment 14 maythen be blended into polyol 10 of mixture 16 by known processes. Forexample, dispersing tank 17 may have a mixing blade 18 of a known typetherein, as well as a motor 19 associated with mixing blade 18, as knownin the art, to rotatably drive mixing blade 18. Preferably, the forcewith which polyol 10, fragrance 12, and pigment 14 are blended isadequate to form a substantially homogeneous mixture 16 withoutintroducing an undesirable amount of gas into mixture 16 and withoutforming an undesirable number of gas bubbles within mixture 16.

As shown in FIG. 2, once the components of mixture 16 have been blended,mixture 16 may be added (e.g., by way of dispersing tank 17) to anadditional quantity of polyol 10 to form a secondary mixture 16′ inwhich the concentration or concentrations of fragrance 12 and pigment14, if any, are diluted. Of course, if mixture 16 is added to anadditional quantity of polyol 10 as depicted in FIG. 2, mixture 16 andpolyol 10 may be blended with one another to form a substantiallyhomogeneous secondary mixture 16′.

FIG. 3 depicts the removal of any gas or gas bubbles 20 from mixture 16or secondary mixture 16′. Although FIG. 3 shows the application of avacuum 21 to mixture 16, 16′ to remove gas or gas bubbles 20 therefrom,any known techniques that are suitable for causing gas and gas bubblesto escape a liquid, such as mixture 16, 16′, without facilitatingundesirable effects (e.g., degradation of one or more of the componentsof mixture 16, 16′, an undesired reaction between components of mixture16, 16′ that would not otherwise occur, an undesirable alteration of oneor more of the components of mixture 16, 16′, etc.) may be employed.

Referring now to FIG. 4, mixture 16, 16′ is blended with an appropriateA-side of the polyurethane, or polymerization catalyst, in his case anisocyanate 22, to form a final polymer blend 30. The amount ofisocyanate 22 that is blended with mixture 16, 16′ depends upon thedesired hardness of the finished article of manufacture 40 (FIG, 6).Preferably, about 50 to about 100 parts, by volume, of isocyanate 22 areblended with 100 parts, by volume, polyol 10 to form final polymer blend30. Thus, final polymer blend 30 may have a concentration, by volume, ofabout 50 to about 70 percent polyol 10 and of about 30 to about 50percent isocyanate 22.

As shown in FIG. 4, these materials may be introduced substantiallyconcurrently through a static mix element 24 of a known type and blendedwith one another thereby. Nonetheless, any known processes and equipmentthat are suitable for mixing the A- and B-sides of polyurethane may beused in the present embodiment of the inventive method. The force withwhich mixture 16, 16′ and isocyanate 22 are blended is preferablysufficient to quickly (i.e., before a substantial amount ofpolymerization occurs) form a substantially homogeneous mixture withoutsubstantially introducing gas or gas bubbles into final polymer blend30. In addition to creating a substantially homogeneous mixture ofpolyol 10 and isocyanate 22, blending of final polymer mixture 30 bystatic mix element 24 or otherwise disperses any undissolved components,such as fragrance 12, pigment 14, or other components (e.g., metalflakes, etc.), to a desired degree throughout final polymer blend 30.

With continued reference to FIG. 4, as the substantially homogeneousfinal polymer blend 30 exits static mix element 24, final polymer blend30 is introduced, or poured or cast, into one or more cavities 36 of oneor more molds 32 through channels 34 that are formed between the top ofeach mold 32 and each cavity 36 thereof. Cavities 36 are shaped anddimensioned so as to form an article of manufacture 40 (FIG. 6) havingthe desired shape and dimensions. As depicted, cavities 36 of molds 32are spherical in shape and have dimensions that are useful for formingbowling balls from final polymer blend 30 upon polymerization or curingof the same. Each mold 32 preferably includes at least two separableportions 32 a and 32 b to facilitate the removal of an article ofmanufacture 40 (FIG. 6) from each cavity 36.

When final polymer blend 30 has been introduced into cavities 36 ofmolds 32, isocyanate 22 and polyol 10 are permitted to polymerize, orcure, solidify, or gel, forming an article of manufacture 40 within eachmold cavity 36. For example, final polymer blend 30 may be permitted togel for about two minutes or longer before article of manufacture 40 isremoved therefrom, as depicted in FIG. 5. The polymerization reactionbetween isocyanate 22 and polyol 10 of final polymer blend 30 isexothermic, or heat generating. This exothermic reaction may cause finalpolymer blend 30 and mold 32 to be heated to temperatures as high asabout 300° F. or greater.

The material of article of manufacture 40 is permitted to cure for anadditional period of time (e.g., a few hours or overnight). As articleof manufacture 40 cures, it may also shrink somewhat, preferably tosubstantially a desired size for the finished article of manufacture 40(FIG. 6). Upon curing to a sufficient degree, finishing processes may beconducted on article of manufacture 40, as known in the art. Whenarticle of manufacture 40 is a bowling ball, finishing processesincluding lathing to remove any irregularities from the surface thereof,engraving, and polishing may be conducted thereon.

Referring now to FIG. 6, a finished article of manufacture 40incorporating teachings of the present invention is preferably asubstantially nonporous structure. Article of manufacture 40 may also besubstantially rigid. When article of manufacture 40 is a bowling ball,as is depicted, the size and weight of the bowling ball are preferablywithin the specifications that have been set by the United StatesBowling Congress, although bowling balls of other dimensions andweights, including child-sized bowling balls and solid and hollow toybowling balls, are also within the scope of the present invention.

When fragrance 12 (FIG. 1) is dissolved within, dispersed substantiallythroughout, or otherwise embedded in the material of article ofmanufacture 40, the aroma of fragrance 12 may be continuously andgradually released from article of manufacture 40 over periods of timereaching about a year or more. Consequently, fragrance 12 may mask odorsthat may be absorbed into the material of article of manufacture 40, aswell as those of the material or materials of article of manufacture 40.Fragrance 12 may also cause the material of article of manufacture 40 toresist absorption of such odors.

Although FIG. 6 depicts the finished article of manufacture 40 as beinga bowling ball, the present invention includes other scented articles ofmanufacture. Moreover, while the method of the present invention hasbeen described in terms of forming a polyurethane article of manufacture40, scented, substantially nonporous articles of manufacture 40incorporating teachings of the present invention may also be formed fromdifferent types of materials, as well as by alternative methods. Whenarticle of manufacture is a bowling ball, it may have a hardness, ordurometer, of about 72 Shore D to about 77 Shore D. Of course, othertypes of articles of manufacture may have different hardnesses.

For example, an article of manufacture 40 of the present invention, suchas a bowling ball, may be formed from a thermosetting resin, in whichcase a suitable fragrance is dissolved in or dispersed throughout aquantity of liquid thermosetting resin, the thermosetting resinintroduced into a cavity of an appropriate mold and heat and/or pressureapplied to the thermosetting resin within the mold cavity to cure thesame.

As another example, a suitable fragrance may be mixed with a quantity ofa suitable thermoplastic resin (which is typically commerciallyavailable in a pellet form) either before or after heat and/or pressureare applied to the thermosetting resin to liquify the same. A mixtureincluding at least the liquified thermosetting resin and fragrance isthen introduced into a cavity of an appropriate mold and permitted tosolidify.

When the finished article of manufacture 40 is a bowling ball, asillustrated in FIG. 6, the bowling ball may or may not include internalor external weighted members that influence the manner in which thebowling ball rolls down a lane.

Although the foregoing description contains many specifics, these shouldnot be construed as limiting the scope of the present invention, butmerely as providing illustrations of some exemplary embodiments.Similarly, other embodiments of the invention may be devised which donot depart from the spirit or scope of the present invention. Featuresfrom different embodiments may be employed in combination. The scope ofthe invention is, therefore, indicated and limited only by the appendedclaims and their legal equivalents, rather than by the foregoingdescription. All additions, deletions, and modifications to theinvention, as disclosed herein, which fall within the meaning and scopeof the claims are to be embraced thereby.

1. A bowling ball, consisting of: a rubber material formed from apolymer blend comprising, before polymerization, a polymerizationcatalyst and a polyol precursor material; at least one fragrancedispersed in at least a portion of the rubber material; and a pigmentdispersed in at least a portion of the rubber material.
 2. The bowlingball of claim 1, wherein a color of the pigment coordinates with an odorof the at least one fragrance.
 3. The bowling ball of claim 1, whereinthe rubber material is substantially nonporous.
 4. The bowling ball ofclaim 1, wherein the at least one fragrance is water-based.
 5. Thebowling ball of claim 1, wherein the at least one fragrance isoil-based.
 6. The bowling ball of claim 1, wherein the rubber materialcomprises a polyurethane.
 7. The bowling ball of claim 1, wherein thebowling ball has a hardness of from about 72 Shore D to about 77 ShoreD.
 8. A bowling ball, consisting essentially of: a nonporous rubbermaterial formed from a polymer blend comprising, before polymerization,a polymerization catalyst and a polyol precursor material; and afragrance at least partially dispersed in at least a portion of thenonporous rubber material.
 9. The bowling ball of claim 8, wherein,after polymerization, the nonporous rubber material has a hardness offrom about 72 Shore D to about 77 Shore D.
 10. The bowling ball of claim8, wherein he fragrance comprises a water-based composition.
 11. Thebowling ball of claim 8, nonessentially including at least one pigment.12. The bowling ball of claim 11, wherein a color of the at least onepigment coordinates with an odor of the fragrance.
 13. A method formanufacturing a bowling ball, comprising: dissolving at least a portionof at least one fragrance into a polyol to form a fragrant polyol;adding a catalyst to the fragrant polyol to form a polymer blend;introducing the polymer blend into a mold; and polymerizing the polymerblend to form a bowling ball.
 14. The method of claim 13, whereindissolving at least a portion of at least one fragrance into the polyolto form a fragrant polyol comprises dissolving an initial quantity ofthe at least one fragrance into the polyol and dispersing an additionalquantity of the at least one fragrance into the fragrant polyol.
 15. Themethod of claim 13, further comprising dissolving a pigment in thepolyol.
 16. The method of claim 13, wherein dissolving at least aportion of at least one fragrance into a polyol to form a fragrantpolyol comprises dissolving up to about 2% by weight of the at least onefragrance in the polyol.
 17. The method of claim 13, further comprising;mixing the fragrant polyol with an additional quantity of polyol todilute at least the at least one fragrance before adding the catalyst tothe fragrant polyol.
 18. The method of claim 13, wherein adding acatalyst to the polyol precursor material to form a polymer blendcomprises adding an isocyanate to the fragrant polyol.
 19. The method ofclaim 13, wherein adding a catalyst to the fragrant polyol to form apolymer blend comprises forming a substantially homogenous mixture ofthe polyol, the at least one fragrance, and the catalyst.
 20. The methodof claim 13, further comprising substantially removing gas or gasbubbles from the fragrant polyol before adding the catalyst.